1.

0 INTRODUCTION
Hindustan Copper Limited (HCL), incorporated on 9th November 1967, is a public sector
undertaking under the administrative control of the Ministry of Mines. It is India’s only
vertically integrated copper producing company as it manufactures copper right from the stage
of mining to beneficiation, smelting, refining and casting of refined copper metal into
downstream sale able products.
The company markets copper cathodes, copper wire bar, continuous cast copper rod
and by-products, such as anode slime (containing gold, silver, etc.). Cathode and continuous
cast copper rods contribute to about 90% of the sales revenue of the company. HCL’s mines
and plants are spread across four operating Units, one each in the States of Rajasthan, Madhya
Pradesh, Jharkhand, Gujarat and Maharashtra as named below:
 Khetri Copper Complex (KCC), Khetrinagar, Rajasthan.
 Gujarat Copper Project (GCP) at Jhagadia, Gujarat.
 Indian Copper Complex (ICC), Ghatsila, Jharkhand.
 Malanjkhand Copper Project (MCP), Malanjkhand, Madhya Pradesh.
 Taloja Copper Project (TCP), Taloja, Maharashtra.

1.1 GENERAL INFORMATION OF KCC:

All the mines at Khetri Copper Complex are Underground and have sufficient surface parting.
KCC has three mines, Khetri mine, Kollihan mine and Chandmari mines. The mining plans of
the above three mines are approved by the Indian Bureau of Mines. The Environmental
Clearance was granted to Khetri and Kollihan mines in March 2009. The sub-level stoping
method was adopted in our Khetri Copper Complex (KCC) mine.The type of the deposit is
pocket-deposit. Blasthole stoping and Sublevel stoping methodsare now practiced in KCC. For
regular ore bodies blast hole stoping is used and for the irregular ore bodies sub-level stoping is
used. The total ore reserves of KCC is 34.11 million tonnes, and the grade average is 1.37%. The
Mine lease area of Khetri, Kollihan and Chandmari are 395.07 Hec, 163.23 Hec and 148.45 Hec
repectively. The current production capacity of Khetri is 0.85 million tonnes per annum and
Kollihan is 1.00 million tonnes per annum.

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Introduction about Khetri Mine:
The Khetri Mining Lease area (M.L.No. 02/92) is situated at the northern tip of the Khetri
Copper Belt. It covers an area of 395.07 hectare. Initially, there were two separate mining leases
namely, Banwas – Gothra Mining lease (297.94 ha) and Banwas Mining Lease (97.13 ha) but at
the request of Hindustan Copper Limited, the Mines and Geology Department of Government of
Rajasthan had approved the proposal for amalgamation of these two leases. The amalgamation of
both Banwas- Gothra and Banwas Mining lease as Khetri Mining lease. In Khetri Mining lease,
Forest area is 164.44 ha and non-Forest area is 230.63 ha. The Khetri mine is then divided into
two blocks namely Khetri Block and Banwas Block.

1.2 LOCATION
Khetri is situated at the foothills of the Aravalli Range, which hosts copper mineralization,
giving rise to a 80 km long metallogenetic province from Singhana in the north to
Raghunathgarh in the south, popularly known as Khetri Copper Belt. Khetri Copper belt forms a
part of the Northern Section of the Khetri Copper Belt which extends 80 km southwards from
Singhana in Jhunjhunu district to Raghunathpur in Sikar District. The deposit is situated within
the latitude 280 00‟ 50” N and 280 01‟ 50” N and longitude 750 45‟ 30” E to 750 47‟ 12” E. It
consists of three major blocks i.e. South Block, Central Block and Northern Block covering a
strike length of 4 km. Khetri copper mine falls in the central blockThe mine lies 160 km North of
State Capital Jaipur and 190 km SSW of National Capital Delhi. Khetri comprises of Khetri town
and Khetrinagar. Khetri town was founded by Raja Khet Singhji Nirwan, and Khetrinagar, which
is about 10 km away from Khetri town, is developed and maintained by Hindustan Copper
Limited.

1.3 INFRASTRUCTURE
The Employees are provided with service of medical care with a hospital, Khetri Nagar Hospital
which is situated 3km away from the mine in the township area. It was established in 1967 and
now has been equipped with modern facilities. For education of the children of employees,
Kendriya Vidyalaya was established near the shopping complex of the township. The township
consists of quarters for the employees, clubs and temple of all religions, markets to ensure they
have a happy and safe environment. For GET (Graduate Engineer Trainees), Two hostel (BTech

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and GET Hostel) has been provided for their accommodation, situated near Pragati Maidan,
Khetri Nagar.

2.0 GEOLOGY
In Geology section, we see about the Topography, Drainage Pattern, Vegetation, Rainfall data of
the area.
2.1 TOPOGRAPHY:
The area forms a part of northern extremity of Aravalli range of hills. There are three NE-SW
striking ranges separated by sandy plains within the lease boundary. Towards west, falls the
eastern foot-hill of Makro Hill range. The Central hill range contains copper mineralisation.
This hill range is separated by Kharkhara valley from Makro hills. On further eastern side,
there is magnetite-quartzite hill of moderate height/ elevation separated by the valley where
different plants, stores, administrative building etc. are located. The highest point of the area is
555 meters above mean sea level and the valley level is around 350 meters above mean sea
level.

2.2 DRAINAGE PATTERN:

There are two seasonal nallas, namely Kharkhara in the west and Sukhnadi on the eastern side
of the KCC. Natural Flow of water in the drainage system of this area has a trend towards NE.
Khetrinagar Township and Gothra village are located towards east of the lease boundary and
Singhana and Kharkhara villages towards north-east and south-west of the lease boundary
respectively.

2.3 VEGETATION:
Vegetation in the area is of Xerophytic adaptations. The bulk of vegetation consists of stunted,
thorny or prickly shrubs and perennial herbs of capable of drought resistance. Distinctly scattered
tress of stunted growth are found along the depressions.

2.4 STRUCTURE:
General strike of the formation is N30E- S30W with steep dips of about 70 due NW. The rocks
around 5000 latitude of Khetri mine takes an easterly swing in strike which changes from N52E-
S68W. The Mineralisation occurs along and around the gradational contact of Ajabgarh and

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Alwar series of Delhi system. All ore lenses of Khetri as well as Banwas blocks parallel to strike
parallel with the host rocks.

Number of transverse faults have been mapped and marked on the surface geological map. One
major transverse fault known as Kudhan fault appears at around 3300-3400 latitude on surface
and it is mapped in each underground mine level also. Its average strike is N60W and dip is 65
due NE. The fault zone shows different width at various mine levels with maximum width of
30m at 300m mine level.

2.5 COPPER MINERALISATION:

Surface Manifesations of copper mineralisation in the form of gossan bands, old workings, huge
mine waste and ash dumps are prominent in the Khetri block, there are no such manifestations
available in Banwas block. Zones of oxidation have been noted upto 15-20m depth.

Main sulphide minerals are Chalcophyite, Pyrrhotite and pyrite. Sulphides occur as stringers,
specks, disseminations and clots. Stringers are more or less aligned parallel to the foliation.
Copper mineralisation is in the form of en-echelon lenses occurring along and around the
gradational contact of Alwar and Ajabgarh series of rocks. Minor amount of gold and silver is
associated with copper mineralisation. Gold and Silver content is more in Banwas block. The
gold. The Gold and Silver content in the Khetri block is 0.2 ppm and 2 ppm respectively while
in Banwas block the gold and silver content is 0.3 ppm and 3.00 ppm respectively.

2.6 CLIMATE:
The general climate of Khetri Nagar can be described as Extreme.

SEASON MAX TEMPERATURE MIN TEMPERATURE

Summer 48 30
Winter 18 2

The diumal variation in temperature is very high indicating typical desert and arid climate. The
rainy season extends normally from July to October.

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2.7 LITHOLOGY:
The rock units of Khetri Mine area are described as follows:
ANDALUSITE PHYLLITE:
It is a persistent rock unit which occurs on the western side of the mining lease area. It is light
to dark gray coloured. At places, it shows porphyroblasts of andalusite / chiastolite.
Discontinuous lenticular bands of quartzite and biotite occur as subordinate intercalations in
phyllite. Small patches of hornblende schist and graphitic phyllites are also encountered. In
between the phyllite and underlying granetiferous schist (footwall side), there exists a
impersistent band of tremolite magnetite rock exposed in the southern end.
GARNET-CHLORITE-QUARTZ SCHIST±AMPHIBOLE AND BIOTITE:
This rock has a clear contact with Andalusite – Phyllites / schist in hanging wall side marked
by abrupt appearance of garnets in borehole cores. The garnetiferous amphibole quartzite /
schist is the main host rock of sulphide mineralization. North of that, garnet starts disappearing
and rock grades into chlorite/biotite/schist. East of garnet-chlorite-quartz schist, amphibole
quartizite/amphibole rick rock starts appearing in patches hosting copper mineralization.
All the rock of this horizon is marked by varying amounts of chlorite, biotite and amphibole
etc. Amphiboles occur as radiating needles and laths. Garnets occur as small dots to
porphyroblasts in size. At places these form clusters and bands growing up to 2 to 3 cm thick.
Chloritization and biotitization of gaernets and amphiboles are noted along the fractures.
AMPHIBOLE QUARTZITE:
This rock is characterized by abundance of amphibole, sparse chlorite and absence of garnet.
Local variation in the rock varies from low amount of amphibole present and high amount of
chlorite present. Amphiboles occur as radiating needles and laths arranged in the form of bands
in siliceous mass. Amphiboles ar biotized at places. The amphiboles rich bands / patches within
amphibole quartzite in Banwas block bear very rich copper mineralization. Feldspars start
appearing and increase in amount with gradual decrease of amphibole as the feldspathic
quartzite horizon is approached in footwall.

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FELDSPATHIC QUARTZITE ASSOCIATED WITH BANDS OF MAGNETITE
QUARTZITE:
This rock underlies the amphibole quartzite. It is light pinkish/grayish colored massive rock. It
contains minor amount of amphibole at places. It also has banded appearance. Feldspathic
character of rock becomes more prominent on weathering. Although minor amount of pyrite is
present, yet appearance of this rock in drill core arks the footwall limit of viable copper
mineralization. There are thin bands of hematite/magnetite quartzite exposed within the
fedspathic quartzite. These bands show minor displacements caused by small transverse faults
occurring in the area.
DOLOMITE/MARBLE:
Surface exposures of dolomite/impure marble are found Banwas area in the horizon of strike
continuity of the host rocks. The marble rock appears to be a significant host rock for cooper
mineralization in Banwas area. It forms intercalated small and large lenses. Well-developed
crystals, thin streaks and bands of amphibole and magnetite occur in appreciable quantity.
INTRUSIVE:
Metabasic dykes cut across the rock formations of the area and also have general parallelism
with the tranverse faults present in the area. Surface exposures have been mapped and shown
on the geological map. At times the metabasic rocks have intruded the transverse faults. Quartz
veins also occur as impersistant thin stringers, blebs, and patches. They also occur as sheeted
zones, which are quite persistent.
PRESENCE OF ORE IN DEPTH:
The ore zones are remarkeably persistent in depth from 450 mRL to (-) 300 mRL in central
part of Khetri Block. The intersection, encountered in bore hole No. BS_28 at (-) 120 mRL
(3.59 % Cu × 46.10 m ) indicates that there is possibility of ore lenses persisting further in
depth below (-) 120 mRL, the ore lenses appear too plunge about 200-250 due NE. This
indicates that the mineralization is likely to extend in depth further along plunge direction i.e.
towards Singhana.

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NATURE OF WALL ROCKS:
There are no surface exposures in the area. The nature of wall rocks as well as host rocks has
been studied on the basis of drill cores only. The borehole cores indicate that wall rocks both
in H/W &F/W of mineralization are competent and because of their sub-vertical dips, these can
work as solid wall/barrier pillar. The mineralized ground, however, appears to be
comparatively less competent because of joints, shears and fractures. The physical and
chemical characteristics of wall rock are suitable for underground mining as experienced in the
adjacent Khetri Mine. The effect of weathering appears to be insignificant.

EXPLORATION:
The various agencies like GSI, AMD, MECL, IBM, Jaipur Mining Corporation and
Hindustan Copper Limited as well have explored this deposit. All together 45 surface bore
holes and 967 underground bore holes totaling 1.15 lakhs metres of diamond drilling has
been done in this area. Khetri Copper Mine is a highly mechanized underground mine
where delineation of ore body in its totality is a must before actual mining operation
starts. Due to difficult topography and increased depth of mine as well as vertical dip
of ore body, it is not possible to explore the deeper levels through surface drilling.
Definition drilling is carried out from the foot wall drives in underground at an interval of
25 meters along the strike to delineate the ore body precisely.

7
3.0 METHOD OF WORKING
3.1 OPERATIONS IN MINE
Operation of a mine starts from the exploration on wards which will give estimation of theore
reserves and so we can define the ore body thereby it is useful for the determination of the
method of working. Before the stoping, mine planning and design will be done. Cyclic
operations suchas drilling, blasting, loading, transportation, ventilation, etc. is carried out.
The following chart depicts the operation of the Khetri mine.

Exploration Feeder Crusher

Defining ore Hoisting by

Ore Pass
body Skip

Tramming by Tramming to
Mine Planning
Locomotives Stockpile

Production
Stope Concentration
Drilling and Execution
preparation Plant
Blasting

3.2 METHOD OF MINING

Sublevel Open Stoping method is used in both Khetri and Banwas Block. In this method, one
sublevel known as Top Sublevel is made between two main level. Stopes are prepared in main
level and sublevel. First, we make a slot in stope for exploration, then make a drill platform
perpendicular to slot, then make a raise between drill level and extraction level. Raise is of 3*3m
which is made by Longhole Blasting Method. After rise is made, Slot Raise is drilled and blasted.
Slot Raise is first drilled and blasted from extraction level at a distance of 12m.Then, remaining
portion is drilled and blasted from drill level. Then, we divide stope into two portions, Trough
Drive and drill drive. First, we blast Trough drive and then blast Drill drive. Parallel holes are
drilled in the slot crosscut and blasted against the preface of the slot raise. This provides an opening
throughout the height of the ore covering the entire width of the ore body. Rings of holes, drilled
in the trough drive and sub levels, are blasted against the preface of the slot.The broken ore falls
into the trough. Where it is loaded into the 5 t GRAN-BY cars by loading equipment (pneumatic)
EIMCO-824 loader. Typically, a stope has one trough drive and one extraction drive. If the ore
body is wider than 20-meter two trough drives and two extraction drives are developed. In that
case one extraction drive is in the hanging wall and another in the foot- wall of the ore body.
3.2.1 REASON FOR SELECTING SUBLEVEL OPEN STOPING
1) Dip of the ore body - The ore body is steeply dipping.
2) Width - The ore body is thick.

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3) Depth - The depth is moderate.
4) Strength of walls - Hang wall, foot wall and the ore body strength
5) Grade of ore body - Ore body is relatively of poor grade.
6) Productivity - Sub-level open stoping method is amenable to
high productivity, which is especially desirable for the poor grade ore mines.
7) Safety - Sub-level open method has the advantage of
being “out of the ore body" mining. The persons working in the stoping area are not exposed to
wide excavations in the stope.

3.3 MODE OF ENTRY

PRODUCTION SHAFT ENTRY:
Production Shaft is used for ore transportation from 0ML level to surface in Khetri Block of mine.
It was made at 3500 latitude and 1210 departure. This is a vertical 5.5 m diameter production shaft
having depth of 477 m. This is also concrete lined. This shaft is equipped with 2870 KW Koepe
winder. It has two skips each of 14 tonnes capacity for hoisting the ore from the mine. The skips
move in shaft on rope guides. (4 ropes each skip).
SERVICE SHAFT ENTRY:
All the levels from 300 ML to 0 ML are connected through service shaft. Service shaft is a vertical
shaft. It is rectangular in shape of 6.11 m length and 4.93 m breadth cross section and is concrete
lined. Service shaft is equipped with 1600 KW double drum winder. It has two cages with double
deck in each cage having a capacity of 44 persons in each deck. Cages move in the shaft on rail
guides provided steel buntons. The shaft is utilized for man-winding, waste rock hoisting and
materials lowering and raising for all levels below. It is also used as main intake for mine
ventilation.
DECLINE MODE OF ENTRY:
The second entry to the mine is 3456 meters long decline at 1:9 gradient right from 424 ML to
(-) 102 ML Opening of the decline up to 297 ML is 5.0 m x 3.0 m to facilitate the movement
of 21 tonnes, below 297 ML the size of the decline becomes 4 m x 3 m. The development of
decline is on progress from 103ML to 0ML dipping with the gradient of 1 in 7 and the decline
is made steeper because cost of operation is too high (`Rs.80,000/m advance). The size of the
decline at present stage is 5m x 3.5 m. The decline is being used for men, material supply,
ventilation, waste handling and use of trackless equipment in Banwas section of the mine.

9
BANWAS VENTILATION SHAFT:
The Shaft is from surface (RL 362.64) to 66 m RL and connected to 240 m RL, 180 m RL, 120
m RL. This is a vertical shaft having 4.5 m diameter and is used as return airway.

SHAFT NO.3 (INCLINE SHAFT):

An incline shaft from surface (374.07 m RL) to 186 m RL) of 4 m width and 3 m breadth size
is used for pumping out the water from 180 m RL sump. This is also used as a 2nd out let from
180 m RL of the mine.

OTHER DETAILS OF THE MINE:

The other important details of the mine can be given as follows
1. Service Raise from 300 MRL to 0 MRL equipped with a separate ladder way.
2. Ventilation Raises at South & North extremities (4.5m X 3.0m).
3. New Ventilation Adit (5.0m X 3.5m) at southern extremity.

3.4 WINDING SYSTEM:

For Production Shaft, Koepe Winding System is used. For Service Shaft, Double Drum
Winding System is used.
KOEPE WINDING SYSTEM:
The skip hoisting is done by friction (Koepe) winder. There are 6 main ropes and 2 tail ropes used
the Koepe winder. The ropes are of the type of fully locked coil. The production shaft is circular
in type and is of the cross section of 5.5m diameter.

No of Ropes 4
Power 800 H.P-2870 KW
Rotational Speed 600 rpm
Diameter of Drum 2438 mm
Gear Ratio 9.43:1
Speed 8m/s
Maximum Loading Capacity 14te
Brake Suspended Caliper Brake
Motor Double Drum helical gear system
Length 580m

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 Brake Drum Size 2794mm
Width of the brake 250mm
Diameter of Tail rope 24mm

DOUBLE DRUM WINDING SYSTEM:

Cage Hoisting is done by Double Drum Winding System.
Power 1600KW drive
Speed 735 rpm
Drum diameter 5000 mm
Width of the drum 1000 mm
No. of drums used 2
Drum surface shape Helical
Gear ratio 19.5:1
Speed (6-14) m/s
Brake type Mechanical brake
Fleet angle 0.65

MAIN ROPE
Diameter 50 mm
Type of the rope Locked coil
Type of the lay Right hand side moderate
Wire breaking strength 165.3 kg/mm
Weight 5.775 kg/m
Factor of safety 82

TAIL ROPE
Diameter 38 mm
Type Non rotating
Breaking strength 61 metric tonnes
Length 528m

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 4.0 DRILLING AND BLASTING
In Banwas block, for lateral development such as Haulage drives, Exploration drives and Stope
development Drill Jumbo is used. In Khetri block, for lateral development Jack Hammer is used.
For vertical development in both blocks, long hole raising and Large dia raising are used. 112mm
diameter is preferred for long hole drilling and 165mm diameter is preferred for the

large diameter drilling. The stope drilling is done by the jumbo drill machine. The man

hole drilling and manual raising are done by the jack hammer. Jack hammer is a

compressed air drill machine where as Jumbo drill is electrically operated. The cable reel

of 100m length is used for the movement of the machine in the underground. The following

steps are followed while drilling:

The face is cleaned by water and loose dressing is done before drilling begins. Then,

the drilling machine will come and the cable is connected to the power. The legs are raised

to give the thrust to the drill bit against the face. The canopy is raised to give the protection

to the operator. The drill rod is raised and the drill bit is placed on the marking. The holes

of 3.2m are driven by the drill rod of 3.4m. The drill bit is button bit. The diameter of the

drill bit is165 mm. Then, the cuttings are removed from the hole by flushing of water

a) By Drill Jumbo

Type of cut Burn cut

Depth of hole 3.0 m
Diameter 55 mm
No. of holes drilled 48
No. of holes 46
charged
Explosive used Emulsion Cartridge 40 mm
Detonator used Electric Half Second Delay (0 to 10)
Charge per delay 17 kg
Powder factor 3.57 kg/m3

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b) By Jack Hammer

Type of cut Burn cut

Depth of hole 1.8 m
Diameter 33 mm
No. of holes drilled 53
No. of holes charged 47
Explosive used Emulsion Cartridge 25 mm
Detonator used Electric half second delay (0 to 9)
Charge per delay 4.8 kg
Powder factor 3.57 kg/m3

c) Long hole raising

Hole diameter 115 mm
No. of holes drilled 21
No. of holes charged 20
Charge Length 3m
Explosive used ANFO
Detonator used Raydet (NONEL) with Booster Cartridge
Charge per delay 16 kg
Powder factor 6.4 kg/m3

d) Large dia raising

Hole Diameter 165 mm

No. of holes drilled 5
No. of holes charged 5
Charge Length 3m (2m Explosive, 1m Stemming)
Explosive used ANFO or Slurry Catridge (125 mm)
Detonator used NONEL with Booster Catridge
Charge per delay 40 kg
Powder factor 7.5 kg/m3

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 5.0 LOADING AND TRANSPORTATION
For loading of broken ore generated in development headings of sub-level, Auto-Loader
(Hopper) is used. These machines can take discharge of 1.5 tonne. In main level
development headings the ore is loaded by rocker shovels (Eimco 824). The pneumatic
shovels load the broken rock either in 3.5 t or in 5.4 t side discharge Granby cars. In
Banwas block of khetri Copper mine development is done by trackless equipments. In
development face loading is done by LHD of 3 tonnes bucket capacity and hauled it by
LPDT of 14 tonnes capacity.
For transport of broken ore & waste, mine cars (Granby cars of 3.5 t, 5.4 t and 7.5 capacity)
are used at different levels of the mine. The loaded cars are hauled by 8t/10t battery
locomotive (MAMC-LB_8) to the various dump yards i.e. ore pass or waste pass. All the ore
reaches the 0 ML via ore pass. From here the ore is transported to the ore bin of capacity 150 T.
The ore is transported to the ore bin by Belt Conveyor of 600 T/h. From the ore bin, ore is passed
through a disc filter which removes ore of size lesser than 250 mm. The remaining ore is sent to
double toggle jaw crusher of capacity 600 T/h, and reduces the size to 250 mm. From the
Crusher, the ore reaches the surge bin (600 T), where with the combination of Vertical Transfer
Door and Horizontal Transfer Door, the ore is loaded into the skip and sent to the surface. The
discharge of the crusher (located below the ore-pass) is conveyed to the surge bin of the
production shaft through a belt conveyor at 16 ML. The ore brought up to the surface with the
help of production shaft skips is conveyed to the concentrator plant through a chain of belt
conveyors via Stockpile.

Loading Equipment
Type Nos Bucket Capacity (in Motive Power
cum)
Rocker Shovel 13 0.425 C/air, 22 HP
LHD 3 4t Diesel,106Hp
2 10t Diesel,250Hp
1 7t Diesel,248Hp

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Haulage Equipment
Type Nos. Size/Capacity Motive Power HP
Locomotive 23 1000 mm Gauge, 20T Elect. Battery 11.2KW 2
DC motors

Belt Conveyor 1 1000 mm wide, 80 m Elect. Motor 30 HP

Long, 600 t/hr
3 30t Diesel Engine
LPDT 3 15t Diesel Engine
1 22t Diesel Engine

Surface Belt Conveyor

Type Nos Size/Capacity Motive Power Hp
Belt Conveyor 1 1200 mm wide 600 Elect. Motor, 50 HP
t/hr 17.5o inclination

6.0 SURVEYING
6.1 LIST OF PLANS MAINTAINED
1. Surface plan
2. Underground plan
3. Transverse section
4. Vertical section
5. Ventilation plan
6. Water-danger plan
7. Geological plan of the area of leasehold
6.2 SOFTWARE USED
AUTOCAD is used for the purpose of plotting the field measurements and preparing the
various plans and sections and also the Data mine is used as a software package in the
mine planning and design.

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 7.0 MECHANICAL SECTION
One of the major requirements of any mining activity is taken care by the Mechanical
Department. The Mechanical Department looks after different mining vehicles and equipment.
The functioning of mechanical department can be differentiated into 2 categories. The Geologists
and the Surveyors after a thorough study of the mine provide the plan and the necessary details
of the mineralized zone to the concerned officials of the mechanical department. Those working
in the diesel section go through the details of the mine and decide on the heavy mining vehicles
to be used for carrying out the necessary operations like drilling, transportation etc. Mechanical
section constitutes of two units such as automobiles or vehicular unit and rock drill unit.
Vehicular unit deals with all the mining machinery that are used in mines, their maintenance,
repairing and water servicing, etc. We will see the specifications of some mechanical devices.

7.1 LOAD HAUL DUMP (LHD):

The LHD used in the mines are of three different capacity and two different companies
belonging to,
Sinome (4 ton – 3 Nos., 10 ton – 2 Nos.)
Eimco Elecon (7 ton – 1 Nos.)
The specifications of the Eimco Elecon LHD – 907 are
Total Length: 9115 mm
Total Loaded weight: 27,000 kg
Tramming Capacity: 7000 kg
Turning Radius: 2555 mm (Inner) and 5640 mm (Outer)
Total Operating Weight:20,000 kg
Type of Engine: Volvo TAD851VE (MSHA – Approved Tier 3) With 6 Inner Cylinder
Turning Angle :45 degrees
7.2 LOW PROFILE DUMP TRUCK (LPDT):
For Muck transportation, 30 tons capacity LPDT are used which are of different make in
the Banwas block of Khetri Mines.
SANDVIK TH430 – 3 Nos.
Eimco Elecon LPDT – 4Nos.

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The specifications of the SANDVIK TH430 are,
Payload Capacity: 30000 kg
Standard Dump Box: 14.5 m3
Speed (Forward & Reverse)
1st Gear: 6.6 km/h
2nd Gear: 11.7 km/h
3rd Gear: 20.5 km/h
4th Gear: 36.6 km/h
Dumping Angle: 61 degrees
Total operating Weight: 28610 kg
Diesel Engine: Volvo TAD1342VE Tier 2
Output: 310 kw (416 hp) @ 2100 rpm

7.3 PASSENGER CARRIER:

In Decline, for transportation of men; passenger carrier are used.
Normet Utimec MF 328 Per vehicle is designed for personnel transportation in small or
medium size tunnel cross sections. It has personnel compartment with seats for 20 persons.
The personnel compartment is designed for safe and easy entry and exit. Door opening is
wide and handrails and non-slip steps are correctly positioned.
Vehicle has optional front and rear axle suspension system that improves driving safety
and comfort and reduces fatigue. The suspension system reduces vibration from wheels to
the front and rear cabins and improves handling of the vehicle. The suspension system
gives efficiency and speed to vehicle usage, with safety and comfort for the passengers
and the driver.
The new Normet FOPS and ROPS approved safety front cabin provides superior visibility
and comfortable compartment for the driver and the passenger. Front cabin is designed for
safe and easy entry and exit. Door openings are wide and handrails and nonslip steps are
correctly positioned. Dashboard is easy and simple to use. New multifunctional display

17
(MID) provides driving information (speed, RPM, temperatures etc.) and information can
be recorded for analysis. Enclosed cabin provides noise level < 75 dB ensuring safe and
comfort driving.
Vehicle layout allows easy access to all service points, all daily checks can be done from
the ground levels.
Personnel compartment: Suspended seats for 32 persons in 8 seats
groups with retractable lap seat belts width- 2400 mm.
Engine: Liquid cooled turbo charged Deutz TCD
2013 L4, 120 kW/2300 rpm, TIER 3
approved
Transmission: Dana 24000 series power shift with pump
drive group 3 speeds forward and reverse 4-
wheel drive
Performance:
1st Gear Max: 6 km/h
2nd Gear Max: 12 km/h
3rd Gear Max: 25 km/h
Fuel Tank: 1121

7.4 BATTERY LOCOMOTIVE

The battery locomotive used in the mine are Chinese make – Xiangtan.

Model: CTY(L) 12/6, 7, 9G

Adhesive Weight: 12 tons
Track Gauge: 600, 762 or 900 mm
Traction: 16.48 kN
Max. Traction: 29.43 kN
Speed: 8.7 km/h

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Voltage: 192 V
Current: 560 A
Length: 5100 mm
Width: 1050, 1212 or 1350 mm
Height: 1600 mm
Wheelbase: 1220 mm
Wheel Diameter: 680 mm

8.0 VENTILATION
The mine is ventilated by two nos. double stage axial flow fans; one of these fans has been
installed at 460 ML on surface whereas the other at the mouth of the decline. A quantity of
20,000 M3 of air is exhausted per minute from the mine by these fans. In spite of these two
main fans auxiliary booster fans have been installed at 0 ML, 124 ML and 246 ML for better
coursing of air at the working places, the intake air is coursing through 424 ML, there after
the production shaft up to the bottom most part of the mine whereas the decline and the
ventilation adit are main return air ways. The loading and transportation of the broken ore
inside the mine is carried out by the diesel equipment. The fumes generated by the diesel
equipment and blasting are diluted towards the safe limit by maintaining the air velocity more
than 30 meters per minute.
Service shaft works as main intake while production shaft and north ventilation shaft
works as main return. The decline constructed for development of Banwas mine also works as
a fresh intake.
1. A 228 HP sirocco axial flow fan of 8400 cubic metre / minute is installed at the
production shaft.
2. A 168 HP sirocco axial flow fan of 5500 cubic metre / minute is installed at the north
ventilation shaft.
3. A 60 HP axial flow fan of 2100 m3 / min is installed at 0 ML NVR I for return air
upto 180 ML (For emergency use)

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The estimation of air quantity requirement is based upon the following factors:
a) Manpower
b) Production and development
c) Dust
d) Explosive

Sl.No Level Production shaft North ventilation shaft Total

Return
1. 240 mRL - 216 216
2. 180 mRL 2520 1712 4232
3. 120 mRL 1320 1880 3200
4. 60 mRL 1600 1580 3180
5. 0 mRL 2755 - 2755
Total 8195 5388 13583

9.0 MINE WATER DEWATERING

Water required for mining operation like drilling, dust suppression, drinking, equipment
cleaning etc. is supplied to the mine through 4’’ diameter water line. From this main water
line at different level it is supplied through pipeline of 2‟ diameter. Used water is
channeled to the main sump. In addition to the water supplied from surface for mine
operation, there is also inflow in the mine through bore holes and fissure zones. Entire
water is collected, into the sumps. There are two sumps in the mine, one at 0 ML of 3875
m3 capacity and another at 180 ML of 4300 m3 capacity.
9.1 SUMP AT 0 ML:
All the water available from Production shaft sump, Service shaft sump and from120 ML
and below is collected in sump at ‘0’ MRL and is pumped to 180 ML main sump. Water
is drawn from Production shaft bottom sump and Service shaft bottom sump to 0 MRL
through pneumatic pumps. The water from different areas of the mine is collected through
system of drainage. The specification of sump is,
Capacity of sump: 3875 cum
Type of pumps: Multi stage turbine pump

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No. of pumps: Three
Power: 170 HP
Head: 244 m
Average pumping capacity: 9 hours per day
SUMP AT 180 ML:
The water generated at 180 ML and above is collected in this sump. As mentioned above
water from 0 ML main sump is also being pumped to this sump. Thus, the total water
available in the mine is pumped to surface by this sump. Average daily pumping hours
are 13 taken together for all the pumps. Enough spare capacity for pumping is also
available at this sump. All the water pumped out from the mine goes to main water tank
of the concentrate plant through Shaft no.3 for further use in beneficiation process. Water
generation at Khetri mine varies between 34,000 m3 to 50,000 m3 per month.
The drainage water collected at the sumps of 180 ML and 0 ML is regularly
checked for its acidity and whenever required lime dosing is done to neutralize the water.
It is confirmed that all the water pumped out of the mine is utilized by plant only and no
water is discharged in open. The specifications of the sump are,
Capacity of sump: 4300 cum
Type of pumps: Multi stage turbine pump
No. of pumps: Four
Power: 170 HP
Head: 244 m

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 10. MINE SUPPORTS
1) The various cross cuts and drives are supported as per the approved Systematic
Timbering Rule in 1.5m x 1.5m grid pattern by 1.8 m long rock bolts.
2) Junctions, sub-stations, grizzlies and pumping stations are supported by 1.2m x 1.2m
grid by 1.8 m long rock bolts.
3) All working areas near the stope block under extraction is additional supported by
timber chocks.
The specifications of the roof bolting are
Length of Roof Bolt: 1800 mm
Drill hole Diameter: 35 mm
Roof bolt Diameter: 25 mm
Thread: 200 mm
Bearing Plate: 15 cm × 15 cm × 6 mm
Grouting Material: Quick setting cement capsule: (1-2 min)

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 11. CONCLUSION

Khetri Copper Mine of Khetri Copper Complex under Hindustan Copper Limited is one of the
most systematically & scientifically worked mechanized mine. It is committed to achieve
consistency and desired target in the long-term objective of ensuring high standard of
environmental and ecological balance conservation of copper reserves and mine safety. It’s
also enhances the living standard of the workers & staffs. The company under going further
expansion to exploit more ore deposit with the help of new upcoming technologies with high
level of safety.

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